Earpiece intra-auricular support system

ABSTRACT

An earpiece including an intra-auricular support, a projection element coupled thereto, and a flexible body disposed thereon and inside an external ear canal of an ear, and a moldable earpiece material moldable about the intra-auricular support to conform to the auricle of an ear and curable to provide a fixed configuration of the earpiece.

This United States Patent Application is a continuation of U.S. patentapplication Ser. No. 16/953,806, filed Nov. 20, 2020, now U.S. Pat. No.11,381,902, issued Jul. 5, 2022, which is a continuation of U.S. patentapplication Ser. No. 16/661,253, filed Oct. 23, 2019, now U.S. Pat. No.10,856,065, issued Dec. 1, 2020, which is a continuation of U.S. patentapplication Ser. No. 16/198,459, filed Nov. 21, 2018, now U.S. Pat. No.10,462,552, issued Oct. 29, 2019, which is a continuation of U.S. patentapplication Ser. No. 15/411,901, filed Jan. 20, 2017, now U.S. Pat. No.10,149,038, issued Dec. 4, 2018, hereby incorporated by referenceherein.

I. TECHNICAL FIELD

An earpiece including an intra-auricular support positionable in anauricle of an ear, a projection element extending a distance outward ofthe intra-auricular support, and a flexible body coupled about theprojection element and configured to engage an external ear canal of anear concurrent with the intra-auricular support positioned in theauricle of the ear, and a moldable earpiece material moldable about theintra-auricular support to conform to the auricle of an ear and curableto provide a fixed configuration of the earpiece.

II. BACKGROUND

Because conventional earpieces may not be configured to the auricle ofthe ear of a wearer, the earpiece may not stay in fixed engagement withthe auricle of the ear, or the earpiece may not correctly align with theexternal ear canal, or the earpiece may be uncomfortable for the wearerto position into or retain in the auricle of the ear.

Additionally, a wide variety of earplugs or in-ear devices to protectagainst or deliver sound to the ear such as medical equipment, headsets,hearing aids, cellular telephones, and the like, include, in part,in-ear devices such as earphones, earplugs, earbuds, ear tips, eartubes, or the like, not configured to the auricle of an individualwearer's ear.

The instant invention provides the advantages of a moldable earpiececonformed to the auricle of the wearer's ear, and which can retain orremovably retain an in-ear device to overcome in whole or in partcertain of the forgoing disadvantages associated with conventionalin-ear devices.

III. SUMMARY OF THE INVENTION

Accordingly, a broad object of the invention can be to provide anearpiece, including one or more of: an intra-auricular support engagableto an auricle of an ear, a projection element outwardly extending fromthe inner surface of the intra-auricular support, a flexible bodydisposed about the projection element and disposable inside the externalear canal of an ear concurrent with the intra-auricular support engagedwith the auricle of the ear, and a moldable earpiece material moldableabout the intra-auricular support to conform to the auricle of the earand curable to provide a fixed configuration of the earpiece.

Another broad object of the invention can be to provide a method ofmaking an earpiece, including one or more of: obtaining anintra-auricular support, coupling a projection element to outwardlyextend from the inner surface of the intra-auricular support, disposinga flexible body about the projection element and configured to engagethe inside of an external ear canal of an ear, providing a moldableearpiece material capable of molding about the intra-auricular supportto conform to the auricle of the ear, and which can further include oneor more of: generating a passage communicating between the outer surfaceof said intra-auricular support and the flexible body second end, andcoupling an intra-auricular support conduit configured to removablyretain an in-ear device to the intra-auricular support.

Another broad object of the invention can be to provide a method formolding an earpiece, including one or more of: obtaining anintra-auricular support having a projection element outwardly extendingfrom the inner surface, and a flexible body disposed about theprojection element, concurrently engaging the intra-auricular supportwith the auricle of an ear and the flexible body with the external earcanal of an ear, molding a moldable earpiece material about theintra-auricular support to conform to the auricle of the ear and curingthe moldable earpiece material to provide a fixed configuration of theearpiece conformed to the auricle of the ear.

Naturally, further objects of the invention are disclosed throughoutother areas of the specification, drawings, photographs, and claims.

IV. A BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a particular embodiment of anintra-auricular support, a projection element coupled to theintra-auricular support, and a flexible body coupled about theprojection element.

FIG. 2 is a side view of the particular embodiment of theintra-auricular support, the projection element, and the flexible body.

FIG. 3 is a front view of the particular embodiment of theintra-auricular support, the projection element, and the flexible body.

FIG. 4 is an exploded perspective view of the particular embodiment ofan intra-auricular support, projection element, and flexible body.

FIG. 5 is a cross sectional side view 5-5 of the particular embodimentof an intra-auricular support, projection element, and flexible bodyshown in FIG. 3 .

FIG. 6A is a particular embodiment of a one-part moldable earpiecematerial “A”.

FIG. 6B is another particular embodiment of a moldable earpiece materialincluding moldable agent “A” and a curing agent “B” combinable togenerate moldable earpiece material “AB”.

FIG. 7 is an illustration of the particular embodiment of anintra-auricular support, projection element, and flexible body havingthe intra-auricular support engaged with the auricle of the earconcurrent with the flexible body disposed in the external ear canal ofan ear.

FIG. 8 is a particular embodiment of the intra-auricular support havingpatterned surface elements as an adhesion element.

FIG. 9A is a particular embodiment of a moldable earpiece materialincluding a tackifier “C” as an adhesion element.

FIG. 9B is another particular embodiment of a moldable earpiece materialhaving a tackifier “C” as an adhesion element.

FIG. 10 is a cross sectional side view of an ear and the particularembodiment of an intra-auricular support, projection element, andflexible body which shows the intra-auricular support engaged with theauricle of the ear concurrent with the flexible body disposed in theexternal ear canal of an ear.

FIG. 11 is a cross sectional side view of the ear and the particularembodiment of an intra-auricular support, projection element, andflexible body engaged with the ear as shown in FIG. 10 and furtherillustrating a moldable earpiece material A or AB moldably engaged withthe intra-auricular support and the auricle of the ear.

FIG. 12 is a cross sectional side view of the ear and the particularembodiment of an intra-auricular support, projection element, andflexible body engaged with the ear as shown in FIG. 11 and furtherillustrating a moldable earpiece material A or AB molded about theintra-auricular support and to the contour of the auricle of the ear toprovide a fixed configuration of the earpiece.

FIG. 13 is a perspective view of a particular embodiment of a fixedconfiguration of an earpiece in an ear.

FIG. 14 is an exploded view of a particular embodiment of anintra-auricular support, a projection element outwardly extending fromthe intra-auricular support and a flexible body coupled about theprojection element and an intra-auricular support conduit disposed inthe intra-auricular support configured to removably retain an in-eardevice.

FIG. 15 is a perspective view of the particular embodiment shown in FIG.14 including the intra-auricular support, the projection element, theflexible body, and the intra-auricular support conduit removablyretaining an in-ear device.

FIG. 16 is a cross sectional side view 16-16 of the particularembodiment of the intra-auricular support having the intra-auricularsupport conduit removably retaining an in-ear device, the projectionelement, the flexible body.

FIG. 17 is a cross sectional side view of the ear and the particularembodiment of an intra-auricular support having the intra-auricularsupport conduit removably retaining an in-ear device, projectionelement, and the flexible body coupled about the projection element andengaged with the external ear canal and further illustrating a moldableearpiece material A or AB molded about the intra-auricular support andto the contour of the auricle of the ear to provide a fixedconfiguration of the earpiece.

FIG. 18 is a perspective view of the particular embodiment of a fixedconfiguration of the earpiece retaining an in-ear device in an ear.

FIG. 19 is an exploded view of the particular embodiment of anintra-auricular support having an intra-auricular support conduitconfigured to removably retain an in-ear device having a body and asound delivery element with the sound delivery element extendablethrough the intra-auricular support conduit to provide a projectionelement, and a flexible body which removably couples to the projectionelement.

FIG. 20 is a perspective view of the particular embodiment of anintra-auricular support having an intra-auricular support conduitremovably retaining an in-ear device having a body and a sound deliveryelement with the sound delivery element extending outwardly from theintra-auricular support to provide a projection element, and a flexiblebody which removably couples to the projection element.

FIG. 21 is a cross sectional side view 21-21 of the particularembodiment of an intra-auricular support having the intra-auricularsupport conduit retaining an in-ear device with the sound deliveryelement extending outwardly from the intra-auricular support to providethe projection element, and the flexible body removably coupled to theprojection element.

FIG. 22 is a cross sectional side view of the ear and the particularembodiment of an intra-auricular support having the intra-auricularsupport conduit retaining an in-ear device with the sound deliveryelement extending outwardly from the intra-auricular support to providethe projection element, and the flexible body engaged with the ear andfurther illustrating a moldable earpiece material A or AB molded aboutthe intra-auricular support and to the contour of the auricle of the earto provide a fixed configuration of the earpiece.

FIG. 23 is a perspective view of the particular embodiment of the fixedconfiguration of the earpiece in an ear.

FIG. 24 is an exploded view of a particular embodiment of anintra-auricular support having an intra-auricular support conduit whichextends a distance outwardly from the outer surface of theintra-auricular support and configured to removably retain an in-eardevice having a body and a sound delivery element with the sounddelivery element extendable outwardly from the inner surface of theintra-auricular support to provide a projection element, and a flexiblebody which removably couples to the projection element.

FIG. 25 is a perspective view of a particular embodiment of anintra-auricular support having an intra-auricular support conduit whichextends a distance outwardly from the outer surface of theintra-auricular support and removably retaining an in-ear device havinga body and a sound delivery element extending outwardly from the innersurface of the intra-auricular support to provide a projection element,and a flexible body which removably coupled to the projection element.

FIG. 26 is a cross sectional side view 26-26 of the particularembodiment of an intra-auricular support having the intra-auricularsupport conduit retaining an in-ear device with the sound deliveryelement extending outwardly from the intra-auricular support to providethe projection element, and the flexible body removably coupled to theprojection element.

FIG. 27 is a cross sectional side view of the particular embodiment ofthe intra-auricular support having the intra-auricular support conduitretaining an in-ear device with the sound delivery element extendingoutwardly from the intra-auricular support to provide the projectionelement, and the flexible body engaged with the external ear canal ofthe ear and further illustrating a moldable earpiece material A or ABmolded about the intra-auricular support and to the contour of theauricle of the ear to provide a fixed configuration of the earpiece.

FIG. 28 is a perspective view of the particular embodiment of the fixedconfiguration of the earpiece in an ear.

FIG. 29 is an exploded view of the particular embodiment of anintra-auricular support having an intra-auricular support conduitincluding a flexible elastomer insert configured to removably retain anin-ear device a projection element extending outward from the innersurface of the intra-auricular support, and a flexible body whichremovably couples to the projection element.

FIG. 30 is a perspective view of the particular embodiment of anintra-auricular support having an intra-auricular support conduitincluding a flexible elastomer insert removably retaining an in-eardevice, a projection element extending outwardly from theintra-auricular support, and a flexible body removably coupled to theprojection element.

FIG. 31 is a cross sectional side view 31-31 of the particularembodiment of an intra-auricular support shown in FIG. 30 having theintra-auricular support conduit including a flexible elastomer insertretaining an in-ear device.

V. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Generally referring to FIGS. 1 through 31 , particular embodiments of anearpiece (1) can include one or more of: an intra-auricular support (2),a projection element (3), a flexible body (4), and a moldable earpiecematerial (5). The intra-auricular support (2) can have an outer surface(6) opposite an inner surface (7), where each surface extends to anintra-auricular support peripheral edge (8). The intra-auricular support(2) extending to the intra-auricular support peripheral edge (8) can beconfigured to be positioned within an auricle (9) of the ear (10). As toparticular embodiments, the intra-auricular support (2) can bepositioned within the area of the auricle (9) of the ear (10)anatomically defined by the antihelix (11), tragus (12), antitragus(13), and concha (14), also referred to herein as the concha bowl (15),and concurrently defining an inner surface (7) of the intra-auricularsupport (2) of sufficient area which precludes ingress of the externalear canal opening (16)(as shown in the example of FIG. 7 ). For purposesof this invention the term “external ear canal (17)” means the portionof the ear canal (or auditory canal) communicating between the auricle(9) of the ear (10) and the tympanic membrane (19). For purposes of thisinvention, the term, “auricle (9)” means the area of the ear (10)outside of the external ear canal (17) including the concha bowl (15)and extending to the peripheral edge (20) of the ear (10)(also referredto as the “ear pinna”).

Now referring primarily to FIGS. 3 and 7 , as to particular embodiments,the intra-auricular support (2) can be configured to be positioned inthe concha bowl (15) concurrent with the flexible body (4) engaged withthe external ear canal (17). While the intra-auricular supportperipheral edge (8) of the embodiment shown in FIGS. 3 and 7 generallydefines a quadrilateral having a pair of linear opposed sides (21)interconnected by a pair of arcuate sides (22), this example of theconfiguration of the intra-auricular support (2) is not intended topreclude other configurations of the intra-auricular support (2) inwhich the intra-auricular support peripheral edge (8) can generallydefine a circle, an ellipse, triangle, or other configuration disposablein the auricle (9) of the ear (10) and, more particularly, disposedwithin the concha bowl (15).

Now referring primarily to FIGS. 7 and 10 , the intra-auricular support(2) can be configured to be disposed in the concha bowl (15) andretained in the concha bowl (15) by contact of the antihelix (11),antitragus (13), or tragus (12) with the corresponding portions of theintra-auricular support (2). As shown by the example of FIG. 7 , a topportion (23) of the intra-auricular support peripheral edge (8) can bedisposed behind the antihelix (11), and the lower portion (24) of theintra-auricular support peripheral edge (8) can be disposed behind theantitragus (13) and tragus (12).

Embodiments of the intra-auricular support (2) can fabricated, formed ormolded from a wide variety of rigid or elastic thermoplastics including,but not necessarily limited to, acrylic, nylon, acrylonitrile butadienestyrene, polylactic acid, polybenzimidzole, polycarbonate, polyethersulfone, polyethylene, urethane, silicone, or combinations thereof.

Now referring primarily to FIGS. 4 and 5 , particular embodiments of theearpiece (1) can further include a projection element (3) outwardlyextending from a location on the inner surface (7) of theintra-auricular support (2) which aligns the projection element (3)within the external ear canal (17) concurrent with the intra-auricularsupport (2) being disposed within the auricle (9) or concha bowl (15) ofthe ear (10). As to particular embodiments, the projection element (3)can be disposed on, coupled to, or directly coupled to the inner surface(7) of the intra-auricular support (2) at a location where theprojection element (3) extends into the external ear canal (17)concurrent with the intra-auricular support (2) being disposed withinthe concha bowl (15) locating the inner surface (7) adjacent to theexternal ear canal opening (16). As exemplified in FIGS. 4 and 5 , thelocation from which the projection element (3) can extend, the bottomportion of inner surface (7) of the intra-auricular support (2), can beproximate the intra-auricular support peripheral edge (8). Theprojection element (3) can be configured as a solid or tubular elongatemember having circular, oval, square, rectangular, or cross sectionalconfiguration otherwise disposable in the external ear canal (17).

The projection element (3) can comprise the same material(s) ordifferent material(s) as the intra-auricular support (2), and as toparticular embodiments, the intra-auricular support (2) and theprojection element (3) can, but need not necessarily, be fabricated,formed or molded in one piece.

Again, referring generally to FIGS. 1 through 5 and FIGS. 10 through 31, particular embodiments of the earpiece (1) can, but need notnecessarily, include a flexible body (4) disposed about the projectionelement (3). The flexible body (4) can be disposed inside of theexternal ear canal (17) of an ear (10) concurrent with theintra-auricular support (2) engaged within the auricle (9) or the conchabowl (15) with the inner surface (7) adjacent the external ear canalopening (16). Embodiments of the flexible body (4) can, but need notnecessarily, comprise any one or a combination of pliant materials orbladders which deformably compress upon engagement with the external earcanal (17) and return toward the original configuration upondisengagement with surfaces of the external ear canal (17), such asfoam, foam rubber, or hydrogel. As to particular embodiments, theflexible body (4) can further include a continuously smooth externalsurface (25).

As to particular embodiments, the flexible body (4) can, but need notnecessarily, be integrated with the projection element (3) as one pieceor, as to other embodiments, removably coupled or connected to theprojection element (3), as illustrated in the example of FIG. 4 . Inparticular embodiments where the flexible body (4) removably couples tothe projection element (3), the flexible body (4) can include a passage(26) disposed in the flexible body (4) and configured to accept theprojection element (3). As illustrated in FIG. 5 , the projectionelement (3) can be configured as a solid cylinder which can insertinglydisposed in the flexible body passage (26) of the flexible body (4). Asto particular embodiments, the flexible body (4) can further include aflexible body conduit (27) having a flexible body conduit internalsurface (28) which defines the flexible body passage (26) and anexternal surface (29) which engages the flexible body (4). The flexiblebody conduit (27) can further include an annular flange (30) extendingradially outward from the passage first end (31) toward the externalsurface (29) of the flexible body (4). As to particular embodiments, theflexible body conduit (27) and the annular flange (30) can comprise onepiece. In other particular embodiments, as illustrated in FIGS. 1 and 3, the flexible body conduit (27) can, but need not necessarily, comprisetwo components where the first component (32) comprises the flexiblebody conduit (27) disposed within the passage (26) of the flexible body(4), and the second component (33) comprises the annular flange (30)coupled to the flexible body first end (34) and radially extendingoutward from the first component (32) disposed in the passage (26)toward the external surface (29) of the flexible body (4).

Now referring primarily to FIGS. 6A and 6B, and 11 through 13, 17, 18,22, 23, 27 and 28 , particular embodiments of the earpiece (1) can, butneed not necessarily, further include a moldable earpiece material (5).The moldable earpiece material (5) can be molded about theintra-auricular support (2) to conform to the auricle (9) or the conchabowl (15) of the ear (10). The moldable earpiece material (5) can, butneed not necessarily be, a single compound (35) (shown as compound “A”in FIG. 6A).

As to other embodiments, the moldable earpiece material (5) can, butneed not necessarily, comprise a two-part moldable earpiece material(37) including or consisting of a moldable agent (38) (shown as compound“A” in FIG. 6B) combinable with a curing agent (39) (shown as compound“B” in FIG. 6B) which can be mixed together prior to molding to form asingle mixed compound (40) (shown as compound “AB” in FIG. 6B) capableof being moldable about, coupled to, or adhering to the intra-auricularsupport (2) by forcibly urging the single mixed compound (40) onto orabout the intra-auricular support (2) (as shown in the example of FIGS.11 and 12, 17 and 18, 22 and 23, and 27 and 28 ). Concurrently, themoldable earpiece material (5), whether a one-part moldable earpiecematerial (36) or a two-part moldable earpiece material (37) to provide asingle mixed compound (40), can be molded to the contour of the auricle(9) or the concha bowl (15) of the ear (10) (as shown in the example ofFIGS. 12 and 13, 17 and 18 , and 22 and 23). After molding about theintra-auricular support (2), the single compound (35) or single mixedcompound (40) can then cure over a period of time at ambient temperature(or at a temperature greater or lesser than ambient temperature) toprovide a fixed configuration of the moldable earpiece material (5)(asshown in the examples of FIGS. 13, 18, and 23 ).

In embodiments including a moldable earpiece material (5) comprising orconsisting of a single compound (35), the single compound (35) caninclude or consist of one or more of: ethyl vinyl acetate,polycaprolactone, silicone, or like thermoplastic materials. Singlecompound (35) moldable earpiece materials (5) transition from a moldablecondition to the fixed condition by exposure to external factors such asmoisture, temperature, or ultraviolet light.

As one illustrative example, the single compound (35) can be an amountof polycaprolactone polymer (CAS No.: 24989-40-4) having the propertiesdescribed in Table 1; however, this illustrative example is not intendedto preclude the use of other thermoplastic polymers suitable for usewith embodiments of the earpiece (1).

TABLE 1 Physical Properties of Polycaprolactone Thermoplastic PolymersPhysical Property ASTM Test Molecular Weight Mn GPC, THF, 25° C. 37,000± 2000; 47500 ± 2000;  69000 ± 1500 Mw GPC, THF, 25° C.  84500 ± 1000;120000 ± 2000 Mz GPC, THF, 25° C. 130000 ± 5000; 178500 Polydispersity(Mw/Mn) 1.78 1.74 Melt Flow Index D 1238  80° C., 2.16 kg, g/10 min 2.360.59  80° C., 21.6 kg, g/10 min 34.6 9.56 190° C., 2.16 kg, g/10 min 287.29 Thermal Analysis (DSC) Melting Point ° C. 60-62 60-62 Heat OfFusion, DHm, J/g 76.9 76.6 Crystallinity, % 56 56 CrystallisationTemperature, ° C. 25.2 27.4 Glass Transition Temperature, Tg,° C. −60−60 Tensile Properties Yield Stress, s y, Mpa D 412-87 100 mm/min 17.516 500 mm/min 17.2 14 Modulus, E. Mpa D 412-87  1 mm/min 470 440  10mm/min 430 500 Draw Stress, s d, MPa D 412-87 100 mm/min 12.6 11.9 500mm/min 11.5 11 Draw Ratio, l d, x D 412-87 100 mm/min >4.2 4 Stress AtBreak, s b, Mpa D 412-87 100 mm/min 29 54 Strain At Break, e b, % 100mm/min D 412-87 >700 920 Flexural Modulus, E, MPa  2 mm/min D 790 411 ndHardness D 2240 Shore A 95 94 Shore D 51 50 Viscosity Pa. sec, 70° C.,10 1/sec 2890 12650 Pa. sec, 100° C., 10 1/sec 1353 5780 Pa. sec, 150°C., 10 1/sec 443 1925

Polycaprolactone polymers can be heated to achieve a moldable condition,molded about the intra-auricular support (2), and contoured to theconfiguration of the auricle (9) or concha bowl (15) and cooled toachieve the fixed configuration of the earpiece (1).

Polycaprolactone polymers impart good water, oil, solvent, and chlorineresistance. Polycaprolactone polymers are also compatible with a widerange of other materials (collectively referred to as “admixed agents”),such as: starch, to impart greater biodegradability; colorants, such asalcohol dyes or acrylic coloring agents; powders, such as acrylicpowder; particulates of plastic, copolymer plastics, metal, bismuthoxychloride, or glitter, or the like, either separately or in variouscombinations. Polycaprolactone polymers are non-toxic and approved bythe United States Food and Drug Administration for specific applicationsin the human body.

In embodiments including a moldable earpiece material (5) comprising orconsisting of a single mixed compound (40), the single mixed compound(40) can include a crosslinkable polymer (compound “A”) having at leastone hydrolysable silane group, selected from the group including orconsisting of: silane-modified polyoxyalkylenes, polyolefins,poly(meth)acrylates, polyurethanes, polyamides, and polysiloxanes;silicone putty partially hydrolyzed alkyl silicate, or combinationsthereof, and a catalyst (compound “B”) including: a metallic salt of anorganic carboxylic acid catalyst in which the metal comprises orconsists of one or more of a platinum, tin, copper, or other metal.

One illustrative example of a single mixed compound (40) including amoldable agent (38) and curing agent (39) comprises polydimethylsiloxanepolymer and platinum (0)-1,3-divinyl-1,1,3,3-tetramethyldisiloxanecuring agent (39). Another illustrative example of a single mixedcompound (40) including a moldable agent (38) and curing agent (39)comprises two proprietary compounds manufactured by Radians, Inc.,silicone putty A-side and silicone putty B-side, of which one siliconeputty contains methylpolysiloxanes.

Yet another illustrative example includes SILPURAN® 8020, a platinumcatalyst-curing solid silicone rubber available through Wacker ChemieAG.

TABLE 2 Physical Properties of SILPURAN ® 8020 Hardness - Shore A (DIN54615) 62 Cure System Platinum (100:1.5 Base + catalyst) SpecificGravity (DIN 54589 A) 1.16 g/cm³  Tensile Strength (DIN 54614S1) 10.5N/mm² Elongation at break (DIN54614S1) 751%  Rebound Resilience(DIN54622) 58% Tear Resistance (ASTM D624B)  30 N/mm² Comprssion set (22h/175° C.) 30% (DIN ISO815-B) Appearance - Translucent

Now generally referring to FIGS. 1 through 31 , embodiments of theintra-auricular support (2) can, but need not necessarily, include oneor more aperture elements (41) which communicate between the outersurface (6) and the inner surface (7) of the intra-auricular support(2). As shown in the examples of FIGS. 11 and 12 , the moldable earpiecematerial (5) can pass through the aperture elements (41) to envelop boththe outer surface (6) and inner surface (7) of the intra-auricularsupport (2) and further allow the moldable earpiece material (5) toconform to the auricle (9) or concha bowl (15) of the ear (10).Additionally, by engaging the moldable earpiece material (5) with theone or more aperture elements (41), a greater surface area of theintra-auricular support (2) can be integrated with the moldable earpiecematerial (5) than if the moldable earpiece material (5) only engaged theouter surface (6), thereby making the cured moldable earpiece material(5) less likely to separate in whole or in part from the intra-auricularsupport (2).

Now referring primarily to FIG. 8 , embodiments of the intra-auricularsupport (2) can, but need not necessarily, include adhesion elements(42). As to particular embodiments, the adhesion elements (42) can beconfigured as patterned surface elements (44) disposed on or in theouter surface (6) or inner surface (7) of the intra-articular support(2). The patterned surface elements (44) can provide an irregular oruniform pattern, texture, or roughness sufficient to fix or reducetravel of the moldable earpiece material (5) on or about theintra-auricular support (2). As to certain embodiments, the patternedsurface elements (44) can provide recesses disposed in theintra-auricular support (2), which can function to sequester themoldable earpiece material (5) (as shown in FIG. 8 ), or provideprotuberances that extend outward of the intra-auricular support (2) topenetrate the moldable earpiece material (5), or combinations thereof.The patterned surface elements (44) can be one piece with theintra-auricular support (2) or can be applied to the intra-auricularsupport (2) as a layer or individual elements.

Now referring primarily to FIGS. 9A and 9B, as to particular embodimentsof the intra-auricular support (2), the adhesion elements (42) cancomprise a tackifier (43) (shown in FIGS. 9A and 9B as compound “C”)incorporated into the moldable earpiece material (5) or applied to theinner surface (7) or the outer surface (6) of the intra-auricularsupport (2) to increase the tack, or stickiness, of the moldableearpiece material (5) or intra-auricular support (2). As illustrativeexamples, the tackifier (43) can include or consist of one or more ofrosin resins, hydrocarbon resins, terpene resins, or other likematerials.

Now referring generally to FIGS. 14 through 31 , particular embodimentsof the earpiece (1) can be provided separate from, but capable of usewith, one or more of a wide variety of in-ear devices (45), for example:earphones, earplugs, earbuds, sealing balloons, ear tips, ear tubes, earspeakers, and in-ear hearing aids, or the like. As to particularembodiments, the in-ear devices (45) can be a part of an apparatus wornor which resides outside of the ear (10), for example: headsets, headphones, telephones, BLUETOOTH® headphones, wireless headphones, hearingaids, medical apparatus, or the like.

Particular embodiments of the earpiece (1) capable of use with an in-eardevice (45) can include an intra-auricular support conduit (46)communicating between the outer surface (6) of the intra-auricularsupport (2) and the inner surface (7) of the intra-auricular support(2). The intra-auricular support conduit (46) can have anintra-auricular support conduit internal surface (47) configured toretain or releasably retain the in-ear device (45) in the earpiece (1)and which defines an intra-auricular support passage (48). Theconfiguration of the intra-auricular support conduit internal surface(47) of the intra-auricular support conduit (46) can vary betweenembodiments to retain or releasably retain a wide variety ofconfigurations of the in-ear device (45) including those configurationsof the in-ear device (45) having a body (49) and a sound deliveryelement (50) which extends outward of the body (49) (as shown in theexamples of FIGS. 19 through 28 ), or those configurations of the in-eardevice (45) having a body (49) without a sound delivery element (50)which extends outward of the body (49) (as shown in the examples ofFIGS. 14 through 18 and 29 through 31 ).

Now referring primarily to FIGS. 14 through 18 , as to particularembodiments useful with in-ear devices (45) without an extended sounddelivery element (50), the intra-auricular support (2) can include anintra-auricular support conduit (46) having an intra-auricular supportconduit internal surface (47) communicating between an intra-auricularsupport conduit first end (51) open at the outer surface (6) of theintra-auricular support (2) and an intra-auricular support conduitsecond end (52) open at the flexible body second end (53) and definingan intra-auricular support passage (48). The intra-auricular supportconduit (46) can be configured proximate the intra-auricular supportconduit first end (51) to releasably retain the in-ear device (45). Theconfiguration of the intra-auricular support conduit internal surface(47) can vary between embodiments to retain or releasably retain a widevariety of configurations of the in-ear device (45). The intra-auricularsupport conduit passage (48) communicates from the outer surface (6) ofthe intra-auricular support (2) to the inner surface (7) of theintra-auricular support (2), through the projection element (3), andthrough the flexible body (4) to the flexible body second end (53) forthe transmission of sound from the in-ear device (45) releasablyretained at the intra-auricular support conduit first end (51) to theflexible body second end (53).

Now referring generally to FIGS. 19 through 28 , as to particularembodiments useful with in-ear device (45) including a sound deliveryelement (50) which projects outward of the body (49) of the in-eardevice (45), the projection element (3) extending outward of the innersurface (7) of the intra-auricular support (2) can comprise or besubstituted by the sound delivery element (50) of the in-ear device (45)and the flexible body (4) can be removably coupled to the sound deliveryelement (50) of the in-ear device (45). As to these embodiments, thepassage (26) disposed in the flexible body (4) can be configured toinsertingly receive, in part or the entirety, the sound delivery element(50) of in-ear device (45).

Now referring primarily to FIGS. 19 through 23 , as to particularembodiments of the earpiece (1) which accommodate an in-ear device (45)having a sound delivery element (50) extending outward of the body (49),the an intra-auricular support conduit (46) can have an intra-auricularsupport conduit first end (51) disposed at the outer surface (6) of theintra-auricular support (2) and an intra-auricular support conduitsecond end (52) disposed at the inner surface (7) of the intra-auricularsupport (2). The intra-auricular support conduit internal surface (47)can be configured to releasably retain the body (49) of in-ear device(45) with the sound delivery element (50) extending outward of the innersurface (7) of the intra-auricular support (2). The intra-auricularsupport conduit passage (48) communicates from the outer surface (6) ofthe intra-auricular support (2) to the inner surface (7) of theintra-auricular support (2) and through the flexible body (4) to open atthe flexible body second end (53) for the transmission of sound from thein-ear device (45) releasably retained at the intra-auricular supportconduit first end (51) to the flexible body second end (53).

Now referring primarily to FIGS. 24 through 28 , as to particularembodiments the intra-auricular support (2) can, but need notnecessarily, include a tubular member (56) which extends a distanceoutward from the outer surface (6) of the intra-auricular support (2) tocorrespondingly dispose the intra-auricular support conduit first end(51) a distance outward of the outer surface (6) of the intra-auricularsupport (2). The intra-auricular support conduit internal surface (47)of the tubular member (56) can be configured to releasably retain thebody (49) of the in-ear device (45). As to those in-ear devices (45)having a sound delivery element (50) extending a distance outward of theinner surface (7) of the intra-auricular support (2), the sound deliveryelement (50) extending outward of the intra-auricular support conduitinternal surface (47) can be insertingly received in the flexible body(4) with the conduit passage (48) communicating from the outer surface(6) of the intra-auricular support (2) to the inner surface (7) of theintra-auricular support (2), through the flexible body (4) to open atthe flexible body second end (53) for the transmission of sound from thein-ear device (45) releasably retained at the intra-auricular supportconduit first end (51) to the flexible body second end (53).

As described above and again exemplified in FIGS. 17, 18, 22, 23, 27,and 28 , particular embodiments of the earpiece (1) including an in-eardevice (45) can include a moldable earpiece material (5) moldable aboutthe intra-auricular support (2) to conform to the auricle (9) of the ear(10). The configuration of the embodiment shown in FIGS. 24 through 28confers the advantage of molding the moldable earpiece material (5)around the tubular member (56) extending outward of the outer surface(6) of the intra-auricular support (2), thereby avoiding or reducingingress of the amount of moldable earpiece material (5) in theintra-auricular support conduit passage (48) or in contact with thein-ear device (45).

Now referring to FIGS. 29 through 31 , embodiments can, but need notnecessarily include, a flexible elastomer insert (54) which removablycouples to the intra-auricular support conduit (46) proximate theintra-auricular support conduit first end (51) to provide a flexibleelastomer insert internal surface (55) configured to retain orreleasably retain the in-ear device (45) in the intra-auricular support(2) or the earpiece (1). A plurality of flexible elastomer inserts (54)can provide a plurality of different configurations of the flexibleelastomer internal surface (55) to retain or releasably retain acorresponding plurality of different configurations of the body (49) ofthe in-ear device (45). By interchanging the flexible elastomer insert(54) removably coupled within the intra-auricular support conduit (46) aplurality of different configurations of the flexible elastomer internalsurface (55) can be achieved in one configuration of the intra-auricularsupport conduit (46), whereby a corresponding plurality of in-eardevices (45) of different configuration can be releasably retained.While the illustrative flexible elastomer insert shown in FIGS. 29-31has a particular thickness, this is not intended to preclude embodimentsof greater or lesser thickness and the thickness of particularembodiments can be as great as necessary to retain the in-ear device(45) in the intra-auricular support conduit (46) or the earpiece (1).

Now referring generally to FIGS. 1 through 31 and, more particularly toFIGS. 10, 11 , and 12, a method of using the earpiece (1) can includeobtaining an earpiece (1) including: an intra-auricular support (2), aprojection element (3), a flexible body (4) disposed about theprojection element (3), and a moldable earpiece material (5), disposingthe flexible body (4) in the external ear canal (17) of an ear (10),adjusting the intra-auricular support (2) within the auricle (9) orconcha bowl (15) having the intra-auricular support inner surface (7)disposed substantially adjacent the external ear canal opening (16),pressingly engaging the moldable earpiece material (5) about theintra-auricular support (2), conforming the moldable earpiece material(5) to the auricle (9) or the concha bowl (15) of the ear (10), andcuring the moldable earpiece material (5) to provide a fixedconfiguration of the earpiece (1); the intra-auricular support (2),projection element (3), flexible body (4), and moldable earpiecematerial (5) having been described above.

In particular embodiments, as exemplified in FIGS. 17, 18, 22, 23, 27,and 28 , a method of using the earpiece (1) may further includeobtaining an intra-auricular support conduit (46) having anintra-auricular support conduit (46) configured to releasably retain anin-ear device (45), as described above, and releasably retaining anin-ear device (45) to the intra-auricular support conduit (46). As toparticular embodiments, the method can further include releasablyretaining a body (49) of an in-ear device (45) to the intra-auricularsupport conduit (46) with a sound delivery element (50) extending adistance outward of the inner surface (7) of the intra-auricular support(2), and removably coupling a flexible body (4) about the sound deliveryelement (50).

As can be easily understood from the foregoing, the basic concepts ofthe present invention may be embodied in a variety of ways. Theinvention involves numerous and varied embodiments of an earpiece whichcan be utilized for the production of an earpiece by the process abovedescribed.

As such, the particular embodiments or elements of the inventiondisclosed by the description or shown in the figures or tablesaccompanying this application are not intended to be limiting, butrather exemplary of the numerous and varied embodiments genericallyencompassed by the invention or equivalents encompassed with respect toany particular element thereof. In addition, the specific description ofa single embodiment or element of the invention may not explicitlydescribe all embodiments or elements possible; many alternatives areimplicitly disclosed by the description and figures.

It should be understood that each element of an apparatus or each stepof a method may be described by an apparatus term or method term. Suchterms can be substituted where desired to make explicit the implicitlybroad coverage to which this invention is entitled. As but one example,it should be understood that all steps of a method may be disclosed asan action, a means for taking that action, or as an element which causesthat action. Similarly, each element of an apparatus may be disclosed asthe physical element or the action which that physical elementfacilitates. As but one example, the disclosure of “a moldable earpiecematerial (5)” should be understood to encompass disclosure of the act of“molding an earpiece material”—whether explicitly discussed or not—and,conversely, were there effectively disclosure of the act of “molding anearpiece material”, such a disclosure should be understood to encompassdisclosure of “a moldable earpiece material (5)” and even a “means formolding an earpiece material.” Such alternative terms for each elementor step are to be understood to be explicitly included in thedescription.

In addition, as to each term used it should be understood that unlessits utilization in this application is inconsistent with suchinterpretation, common dictionary definitions should be understood to beincluded in the description for each term as contained in the RandomHouse Webster's Unabridged Dictionary, second edition, each definitionhereby incorporated by reference.

Moreover, for the purposes of the present invention, the term “a” or“an” entity refers to one or more of that entity; for example, “anearpiece” refers to one or more of the earpieces. As such, the terms “a”or “an”, “one or more” and “at least one” can be used interchangeablyherein.

All numeric values herein are assumed to be modified by the term“about”, whether or not explicitly indicated. For the purposes of thepresent invention, ranges may be expressed as from “about” oneparticular value to “about” another particular value. When such a rangeis expressed, another embodiment includes from the one particular valueto the other particular value. The recitation of numerical ranges byendpoints includes all the numeric values subsumed within that range. Anumerical range of one to five includes for example the numeric values1, 1.5, 2, 2.75, 3, 3.80, 4, 5, and so forth. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint. The term “about” generally refers to a range of numeric valuesthat one of skill in the art would consider equivalent to the recitednumeric value or having the same function or result.

Similarly, the antecedent “substantially” means largely, but not wholly,the same form, manner or degree and the particular element will have arange of configurations as a person of ordinary skill in the art wouldconsider as having the same function or result. When a particularelement is expressed as an approximation by use of the antecedent“substantially,” it will be understood that the particular element formsanother embodiment.

Thus, the applicant(s) should be understood to claim at least: i) eachof the earpieces herein disclosed and described, ii) the related methodsdisclosed and described, iii) similar, equivalent, and even implicitvariations of each of these devices and methods, iv) those alternativeembodiments which accomplish each of the functions shown, disclosed, ordescribed, v) those alternative designs and methods which accomplisheach of the functions shown as are implicit to accomplish that which isdisclosed and described, vi) each feature, component, and step shown asseparate and independent inventions, vii) the applications enhanced bythe various systems or components disclosed, viii) the resultingproducts produced by such systems or components, ix) methods andapparatuses substantially as described hereinbefore and with referenceto any of the accompanying examples, x) the various combinations andpermutations of each of the previous elements disclosed.

The background section of this patent application provides a statementof the field of endeavor to which the invention pertains. This sectionmay also incorporate or contain paraphrasing of certain United Statespatents, patent applications, publications, or subject matter of theclaimed invention useful in relating information, problems, or concernsabout the state of technology to which the invention is drawn toward. Itis not intended that any United States patent, patent application,publication, statement or other information cited or incorporated hereinbe interpreted, construed or deemed to be admitted as prior art withrespect to the invention.

The claims set forth in this specification, if any, are herebyincorporated by reference as part of this description of the invention,and the applicant expressly reserves the right to use all of or aportion of such incorporated content of such claims as additionaldescription to support any of or all of the claims or any element orcomponent thereof, and the applicant further expressly reserves theright to move any portion of or all of the incorporated content of suchclaims or any element or component thereof from the description into theclaims or vice-versa as necessary to define the matter for whichprotection is sought by this application or by any subsequentapplication or continuation, division, or continuation-in-partapplication thereof, or to obtain any benefit of, reduction in feespursuant to, or to comply with the patent laws, rules, or regulations ofany country or treaty, and such content incorporated by reference shallsurvive during the entire pendency of this application including anysubsequent continuation, division, or continuation-in-part applicationthereof or any reissue or extension thereon.

The claims set forth in this specification, if any, are further intendedto describe the metes and bounds of a limited number of the preferredembodiments of the invention and are not to be construed as the broadestembodiment of the invention or a complete listing of embodiments of theinvention that may be claimed. The applicant does not waive any right todevelop further claims based upon the description set forth above as apart of any continuation, division, or continuation-in-part, or similarapplication.

I claim:
 1. A method of making an earpiece, comprising: configuring anintra-auricular support having an outer surface opposite an innersurface each extending to an intra-auricular support peripheral edge;extending a projection element outward of said inner surface of saidintra-auricular support; disposing a flexible body about said projectionelement, said flexible body disposable inside of an external ear canalof an ear concurrent with said intra-auricular support engaged to anauricle of said ear; and providing a moldable earpiece material adaptedto mold about said intra-auricular support to conform to said auricle ofsaid ear, said moldable earpiece material curable in a fixedconfiguration of said earpiece.
 2. The method of making an earpiece ofclaim 1, further comprising disposing a passage in said intra-auricularsupport and said flexible body, said passage open to said outer surfaceof said intra-auricular support and a second end of said flexible body.3. The method of making an earpiece of claim 2, further comprisingdisposing an intra-auricular support conduit in said intra-auricularsupport communicating between said outer surface and said inner surfaceof said intra-auricular support.
 4. The method of making an earpiece ofclaim 3, further comprising extending said intra-auricular supportconduit a distance outward of said outer surface of said intra-auricularsupport.
 5. The method of making an earpiece of claim 4, wherein saidintra-auricular support conduit extending said distance outward of saidouter surface defines a conduit external surface engageable by saidmoldable earpiece material.
 6. The method of making an earpiece of claim5, further comprising configuring an internal surface of saidintra-auricular support conduit to engage an in-ear device.
 7. Themethod of making an earpiece of claim 5, further comprising configuringan in-ear device to engage an internal surface of said intra-auricularsupport conduit.
 8. The method of making an earpiece of claim 7, furthercomprising providing an in-ear device to engageable by said internalsurface said intra-auricular support conduit.
 9. The method of making anearpiece of claim 8, wherein said in-ear device is selected from thegroup consisting of: earphones, earplugs, earbuds, ear tips, ear tubes,ear-sealing ballons, and in-ear hearing aids.
 10. The method of makingan earpiece of claim 9, wherein said in-ear device further comprises apart of an apparatus which resides outside of said ear.
 11. The methodof making an earpiece of claim 10, further comprising selecting saidapparatus from the group consisting of: headsets, head phones,telephones, BLUETOOTH® headphones, wireless headphones, and hearingaids.
 12. The method of making an earpiece of claim 1, wherein saidmoldable earpiece material comprises a one-part moldable earpiecematerial.
 13. The method of making an earpiece of claim 12, furthercomprising selecting said one-part moldable earpiece material from thegroup consisting of: ethylene vinyl acetate, polycaprolactone, and roomtemperature vulcanization silicone.
 14. The method of making an earpieceof claim 13, wherein said one-part moldable earpiece material comprisesethylene vinyl acetate.
 15. The method of making an earpiece of claim 1,wherein said moldable earpiece material comprises a moldable agent and acuring agent, further comprises combining said moldable agent and saidcuring agent curable in said fixed configuration of said earpiece. 16.The method of making an earpiece of claim 15, wherein said moldableagent and said curing agent comprises a crosslinkable polymer and acatalyst.
 17. The method of making an earpiece of claim 16, wherein saidcrosslinkable polymer comprises a polymer containing at least onehydrolysable silane group and wherein said catalyst comprises one ormore of a metallic salt of an organic carboxylic acid.
 18. The method ofmaking an earpiece of claim 17, wherein said crosslinkable polymercomprises one or more of silane-modified olyoxyalkylenes, polyolefins,poly(meth)acrylates, polyurethanes, polyamides, and polysiloxanes andsaid a metallic salt of an organic carboxylic acid comprises one or moreof a platinum, tin or copper salt of said organic carboxylic acid. 19.The method of making an earpiece of claim 18, wherein said crosslinkablepolymer comprises polydimethylsiloxane and wherein said catalystcomprises platinum (0)-1,3-divinyl-1,1,3,3-tetramethyldisiloxane.
 20. Amethod of making an earpiece, comprising: configuring an intra-auricularsupport having an outer surface opposite an inner surface each extendingto an intra-auricular support peripheral edge; extending a projectionelement outward of said inner surface of said intra-auricular support;disposing a flexible body about said projection element, said flexiblebody disposable inside of an external ear canal of an ear concurrentwith said intra-auricular support engaged to an auricle of said ear; andproviding a moldable earpiece material adapted to mold about saidintra-auricular support to conform to said auricle of said ear, saidmoldable earpiece material curable in a fixed configuration of saidearpiece, said moldable earpiece material comprises ethylene vinylacetate.